Relay adjustment structure and methods

Abstract

There is provided structure and methods for use in adjusting certain design parameters of a relay during initial assembly of the relay. The structure includes an adjustment member insertable between a bobbin and a core. The adjustment member is preferably U-shaped having arms straddling the core and a backspan which acts as a stop to define the travel of an armature. A method of initially adjusting the relay includes inserting the adjustment member between the bobbin and the core and moving the armature into engagement with the backspan. The adjustment member is driven between the bobbin and core and permanently fixed in place when the desired parameters have been attained. An alternative method includes providing a relay having a motor assembly, including a bobbin and core, which may be moved about a pivot point in the relay. The armature is forced against the motor assembly until the desired design parameters are obtained and the motor assembly is then permanently fixed in place within the relay. A further alternative method includes providing a relay having a bobbin fixed with respect to the relay and a core movable within a bore of the bobbin. An armature is forced against the core moving it within the bore of the bobbin until the desired parameters have been obtained. Thereafter, the core is permanently fixed in position within the bore of the bobbin.

What is claimed is: 
     
       1. A method of adjusting a relay comprising the steps of: providing an adjustment member insertable between a bobbin and a core of a relay;   inserting the adjustment member between the core and the bobbin;   driving the adjustment member between the core and the bobbin by forcing an armature against the adjustment member until at least one desired design parameter selected from the group consisting of a contact gap, overtravel and an armature gap associated with the movement of the armature has been obtained; and   maintaining a position of the adjustment member to act as a stop against the armature such that movement of the armature is prevented upon engagement of the adjustment member.   
     
     
       2. The method as recited in claim 1, wherein the step of driving includes the step of driving the adjustment member between the core and the bobbin such that the adjustment member frictionally engages the core and the bobbin. 
     
     
       3. The method as recited in claim 1, further comprising the step of permanently affixing the adjustment member with respect to the core and the bobbin. 
     
     
       4. The method as recited in claim 2, wherein the adjustment member is U-shaped and the step of driving includes driving the U-shaped adjustment member about the core. 
     
     
       5. The method as recited in claim 3, wherein the adjustment member is permanently affixed by gluing. 
     
     
       6. The method as recited in claim 1, wherein the step of driving includes forcing the armature against a back span of the adjustment member.